US20090152759A1 - Shaping die and its use in a solid state drawing process - Google Patents

Shaping die and its use in a solid state drawing process Download PDF

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Publication number
US20090152759A1
US20090152759A1 US12/327,122 US32712208A US2009152759A1 US 20090152759 A1 US20090152759 A1 US 20090152759A1 US 32712208 A US32712208 A US 32712208A US 2009152759 A1 US2009152759 A1 US 2009152759A1
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Prior art keywords
polymer composition
shaping channel
static
die
protrusion
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Abandoned
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US12/327,122
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English (en)
Inventor
Bruce A. Malone
Gregory T. Stewart
Brett M. Birchmeier
Timothy O. Kirch
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Individual
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Priority to US12/327,122 priority Critical patent/US20090152759A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/30—Drawing through a die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/86—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the nozzle zone
    • B29C48/865—Heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/86—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the nozzle zone
    • B29C48/87—Cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • B29C48/908—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article characterised by calibrator surface, e.g. structure or holes for lubrication, cooling or venting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0018—Combinations of extrusion moulding with other shaping operations combined with shaping by orienting, stretching or shrinking, e.g. film blowing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/86—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the nozzle zone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B29K2105/253—Preform
    • B29K2105/256—Sheets, plates, blanks or films

Definitions

  • the present invention relates to a die suitable for use as a solid state drawing die and a process for solid state drawing a polymer composition.
  • hidden fasteners for attaching deck boards to a support structure without having exposed screws or nails.
  • Hidden fasteners require a narrow groove feature along one or more side of the deck boards into which a fastener inserts.
  • flooring applications often benefit from tongue and groove features in opposing sides of a floor board so that the tongue of one board can insert into the groove of an adjoining board.
  • Features such as the tongue and grooves are typically machined into wooden boards by milling out (removing) board material. Such milling requires removing and disposing of board material.
  • WO 01/45915 discloses an OPC article that has tongue and groove features on opposing sides. However, WO 01/45915 does not teach how to form the tongue and groove features on the OPC article. WO 01/45915 does mention that the OPC could be shaped and planed very much like wood, suggesting the tongue and groove features are likely milled into the OPC article after drawing. Milling and machining undesirably require a specific processing step and generate waste that requires disposal. It is desirable to introduce features into an OPC material while drawing it so as to avoid generation of waste.
  • U.S. Pat. No. 5,797,254 discloses a process for preparing a solid oriented polymer rod containing concave grooves.
  • the process exemplified in U.S. Pat. No. 5,797,254 uses rollers, specifically spherical balls, to apply pressure onto a polymer rod within a solid state drawing die in order to introduce concave grooves while orienting the polymer rod.
  • the rollers freely rotate within the drawing die during the drawing process.
  • the die is a dynamic die having moving parts.
  • the moving parts are those applying pressure against a polymer composition being drawn through the die.
  • Such moving parts are desirable in a drawing die in order to minimize frictional forces on a polymer composition during the drawing process, advantages of which are well known and include reduction of drawing stress and reduction of shear flow deformation (see, for example U.S. Pat. No. 4,950,151 incorporated herein by reference in its entirety). These references leave unknown whether grooves can be introduced into a polymer within a drawing die when the drawing die is static (that is, free of moving parts). Static protrusions, as compared to dynamic protrusions, generate higher drawing stresses and there is a greater tendency to tear apart a polymer composition rather than merely deform it.
  • Molten polymer shaping processes are available that are capable of producing polymer articles having groove-like features using static protrusions in shaping dies.
  • Molten shaping processes extrude a molten polymer through a shaping die containing static protrusions extending into the polymer flow path in order to introduce a groove into the polymer material.
  • molten polymers do not undergo orientation. As such, the resulting polymer material is not oriented and does not offer the strength or cavitation characteristics available in an OPC. Still more, a molten polymer can freely conform around a static protrusion so the concern over drawing stress is not applicable.
  • a solid state material is much less malleable than a molten material and so is not generally expected to conform to static protrusions in a die but rather split or dissociate into multiple discrete pieces as the static protrusion divides or tears into the solid state material, if the static protrusion penetrates into the solid material at all. The likelihood of tearing away polymer composition increases as the cross sectional area of the static protrusion increases.
  • use of such shaping die is not typically a converging die and is therefore unsuitable for orienting a polymer composition.
  • the present invention provides a solid state drawing die and process for preparing an oriented polymer composition (OPC) that introduces a groove feature into solid state polymer material while orienting the solid state polymer material through a converging drawing die.
  • OPC oriented polymer composition
  • the process is able to introduce groove features into a solid state material using a static protrusion without dissociating (for example, tearing or fracturing) the solid material into multiple pieces.
  • the present invention is able to introduce groove features into a solid state material without dissociation of the solid state material while inducing orientation into the solid state material through solid state drawing.
  • the static protrusion does not dissociate the polymer composition during the process of the present invention.
  • a solid state material can undergo deformation in a converging drawing die
  • such known art forces deformation by directing polymer composition into itself (that is, forcing polymer composition to converge).
  • a static protrusion in the present invention imparts a dissociating force over a small area of the solid state polymer composition and forces the solid state polymer composition to part (that is, to diverge). This is similar to forcing a wedge of a log splitter into a log.
  • the solid state polymer composition parts around the static protrusion without fracturing, unlike a log when hit with the wedge of a log splitter.
  • a solid state polymer composition conforms to the static protrusion in the present die by being redirected in multiple directions around the static protrusion and yet, despite the diverging displacement, the polymer composition remains intact.
  • the present invention is a solid state drawing die comprising: (i) a body having opposing entrance and exit ends; (ii) a shaping channel providing fluid communication entirely through the body from the entrance to exit end with the exposed body within the shaping channel serving as shaping channel walls wherein the shaping channel has a converging profile; and (iii) at least one portion of the body that serves as a static protrusion extending into but not all the way across the shaping channel.
  • the static protrusion extends into the shaping channel three millimeters or more and 50 millimeters or less as measured perpendicularly from a virtual shaping channel wall underneath the static protrusion;
  • the static protrusion has a cross sectional area of five square millimeters or more and 1000 square millimeters or less;
  • the static protrusion has an impact angle of 30° or more;
  • static protrusion has a planar impact surface;
  • the shaping channel contains multiple static protrusions that define a tongue feature in the shaping channel's cross section and in a polymer material drawn through the shaping channel;
  • the shaping channel further comprises a static protrusion to create a groove in the shaping channel's cross section and in a polymer material drawn through the shaping channel; at least a portion of the static protrusion resides within a portion of the shaping channel within ten millimeters of the exit opening of the die; a portion of the shaping channel most proximate to the exit opening serves as
  • the present invention is a process for solid state drawing of a polymer composition
  • a process for solid state drawing of a polymer composition comprising the following steps: (a) providing a polymer composition having a softening temperature, T s , and comprising a continuous orientable polymer; (b) conditioning the polymer composition to a drawing temperature, T d , that is in a range between T c and 50° C.
  • a solid state drawing die comprising: (i) a body having opposing entrance and exit ends; (ii) a shaping channel providing fluid communication entirely through the body from the entrance to exit end with the exposed body within the shaping channel serving as shaping channel walls wherein the shaping channel has a converging profile; and (iii) at least one portion of the body that serves as a static protrusion extending into but not all the way across the shaping channel; wherein the static protrusion of the drawing die forces displacement of the polymer composition around the static protrusion to create and indentation in the polymer composition without dissociating the polymer composition into two or more distinct pieces during step (c).
  • the process further comprises inserting one or more calibrating probe into the indentation in the polymer composition as the polymer composition exits the drawing die and, desirably, retaining the calibrating probe in the indentation until the polymer composition ceases to draw down in cross sectional area;
  • the static protrusion extends into the shaping channel three millimeters or more and 50 millimeter or less as measured perpendicularly from a virtual shaping channel wall underneath the static protrusion;
  • the static protrusion extends into the shaping channel six millimeters or more and 50 millimeter or less as measured perpendicularly from a virtual shaping channel wall underneath the static protrusion;
  • the static protrusion has an impact angle of 45° or more;
  • the polymer composition simultaneously undergoes displacement around the static protrusion and experiences molecular orientation in the drawing direction;
  • the static protrusion is preferentially heated with respect the rest of the solid state drawing die body; a portion of the shaping channel most prox
  • FIG. 1 Illustrates a main converging portion of a die that, in combination with a land plate containing one or more static protrusion such as those in FIG. 2-6 , forms a die of the present invention.
  • FIG. 2 Provides an illustration of a shaping land plate having opposing static protrusions each characterized by having a rectangular planar impact surface with a 27° impact angle.
  • FIG. 3 Provides an illustration of a shaping land plate having opposing static protrusions each characterized by having a triangular planar impact surface with a 27° impact angle.
  • FIG. 4 Provides an illustration of a shaping land plate having opposing static protrusions each characterized by having a rounded rectangular impact surface with a 37° impact angle.
  • FIG. 5 Provides an illustration of a shaping land plate having opposing static protrusions each characterized by having a rounded triangular impact surface with a 37° impact angle.
  • FIG. 6 Provides an illustration of a shaping land plate having opposing static protrusions each characterized by having a rectangular planar impact surface with a 90° impact angle.
  • Solid state refers to a polymer (or polymer composition) that is below the softening temperature of the polymer (or polymer composition).
  • solid state drawing refers to drawing a polymer or polymer composition that is at a temperature below the softening temperature of the polymer (or polymer composition).
  • Polymer composition comprises a continuous polymer phase containing at least one polymer component and can contain non-polymeric components.
  • Softening temperature (T s ) for a polymer or polymer composition having as polymer components only one or more than one semi-crystalline polymer is the melting temperature for the polymer composition.
  • Melting temperature (T m ) for a semi-crystalline polymer is the temperature half-way through a crystalline-to-melt phase change as determined by differential scanning calorimetry (DSC) upon heating a crystallized polymer at a specific heating rate.
  • DSC differential scanning calorimetry
  • T m for the polymer combination or filled polymer composition is the temperature half-way through the phase change. If multiple crystalline-to-melt phase changes are evident in a DSC curve due to the presence of immiscible polymers, then T m for the polymer combination or filled polymer composition is the T m of the continuous phase polymer. If more than one polymer is continuous and they are not miscible, then the T m for the polymer combination or filled polymer composition is the lowest T m of the continuous phase polymers.
  • T s for a polymer or polymer composition having as polymer components only one or more than one amorphous polymer is the glass transition temperature for the polymer composition.
  • Glass transition temperature (T g ) for a polymer or polymer composition is as determined by DSC according to the procedure in ASTM method E1356-03. Determine T g for a combination of polymer and for a filled polymer composition also by DSC under the same test conditions in ASTM method E1356-03. If the combination of polymer or filled polymer composition only contains miscible polymers and only one glass transition phase change is evident in the DSC curve, then T g of the polymer combination or filled polymer composition is the temperature half-way through the phase change. If multiple glass transition phase changes are evident in a DSC curve due to the presence of immiscible amorphous polymers, then T g for the polymer combination or filled polymer composition is the T g of the continuous phase polymer. If more than one amorphous polymer is continuous and they are not miscible, then the T g for the polymer composition or filled polymer composition is the lowest T g of the continuous phase polymers.
  • the softening temperature of the polymer composition is the softening temperature of the continuous phase polymer or polymer composition. If the semi-crystalline and amorphous polymer phases are co-continuous, then the softening temperature of the combination is the lower softening temperature of the two phases.
  • “Drawing axis” is a line through a shaping channel of a drawing die that extends in the direction that the center of mass (centroid) of a polymer composition is moving as the polymer composition is drawn through the drawing die.
  • the drawing axis lies on a substantially straight line or straight line extending through the shaping channel of a solid state drawing die.
  • “Centroid” refers to a point whose coordinates are the averages of the corresponding coordinates of a given set of points and which for a given plane (for example, a cross section) corresponds to the center of mass of a thin plate of uniform thickness and consistency or a body of uniform consistency having the same boundary.
  • centroid line refers to a line containing the centroid for all cross sections of a die's shaping channel. For identifying the centroid line of a die, identify the centroid for a cross section of the shaping channel using virtual shaping channel walls in place of protrusions. Desirably, the centroid line of a solid state drawing die is a substantially straight line or a straight line. The centroid line lies on the drawing axis.
  • Length of a shaping channel is the distance from the entrance opening to the exit opening along the centroid line.
  • a “substantially straight line” may deviate from perfectly straight.
  • a “substantially straight line” means than any third point located between first and second points that are spaced at least one centimeter apart deviates from a perfectly straight line defined by the first and a second points by 10% or less, preferably 5% or less, more preferably 2% or less. Determine percent deviation by dividing the perpendicular distance of the third point from a line between the first two points by the distance between the first two points and then multiply by 100%.
  • a substantially straight line may be perfectly straight.
  • Cross sections herein are perpendicular to the drawing axis unless the reference to the cross section indicates otherwise.
  • a cross section has a centroid and a perimeter that defines a shape for the cross section.
  • a “cross sectional dimension” is the length of a straight line connecting two points on a cross section's perimeter and extending through the centroid of the cross section.
  • a cross sectional dimension of a rectilinear four-sided polymer composition could be the height or width of the polymer composition.
  • “Drawing temperature” is a temperature within a drawing temperature range at which a polymer is conditioned prior to drawing and is the temperature at which the polymer exists upon the initiation of drawing.
  • a polymer composition typically has a variation in temperature through its cross section (that is, along a cross sectional dimension of the composition) during processing. Therefore, reference to temperature of a polymer composition refers to an average of the highest and lowest temperature along a cross sectional dimension of the polymer composition.
  • the temperature at two different points along the polymer cross sectional dimension desirably differs by 10% or less, preferably 5% or less, more preferably 1% or less, most preferably by 0% from the average temperature of the highest and lowest temperature along the cross sectional dimension. Measure the temperature in degrees Celsius (° C.) along a cross sectional dimension by inserting thermocouples to different points along the cross sectional dimension.
  • Converging profile refers to a shaping channel that reduces in cross sectional area, preferably in a streamline fashion, over at least a portion of the shaping channel when proceeding from the entrance opening of the shaping channel to the exit opening of the shaping channel.
  • a shaping channel has a converging profile if at least one cross section of the shaping channel has a cross sectional area greater than a cross section for the shaping channel more proximate to the exit opening of the shaping channel.
  • any cross section of the shaping channel in a converging die has a cross sectional area that is equal to or greater than the cross sectional area of any other cross section of the shaping channel more proximate to the exit opening of the shaping channel.
  • a “land section” of a shaping channel changes in cross sectional area by five percent or less, preferably two percent or less, more preferably has a uniform cross sectional area at any two points along the drawing axis through the land section.
  • Streamlined flow through a die refers to flow through a die that has been optimized to achieve maximum uniformity of flow and minimum flow resistance, in accordance with the definition in the Richmond reference.
  • flow herein includes movement of polymer chains as they are deformed through a solid state drawing process and does not imply liquid state movement.
  • Protrusion refers to a feature that sticks out from its surroundings.
  • a protrusion is a portion of a die body that sticks out from surrounding portions of the die body and into the shaping channel of a drawing die.
  • a protrusion forces and allows for diverging flow of polymer composition around it as the polymer composition travels through a shaping channel in the present die.
  • a “static protrusion” is a protrusion of a die that does not move with respect to the die while solid state drawing a polymer composition through the die.
  • “Virtual dimension” of a shaping channel is a cross sectional dimension whose magnitude is determined as though the shaping channel is free of protrusions. Measure the magnitude of a virtual dimension from a virtual shaping channel wall associated with any protrusion in the virtual dimension.
  • “Virtual shaping channel wall” is an imaginary line connecting two points on a shaping channel wall cross section on either side of a protrusion and that continues along a trajectory (path) of the shaping channel wall leading up to the protrusion. If the protrusion exists in a corner where two shaping channel walls would meet but for the protrusion, the virtual shaping channel wall is a combination of two imaginary lines continuing the shaping channel wall trajectory (path) of each shaping channel wall prior to the protrusion and meeting as if the protrusion did not exist.
  • “Impact angle” corresponds to an angle that a surface of a protrusion makes with the centroid line just prior to (more proximate to the entrance opening) the protrusion. It is also the angle the surface of the protrusion makes with the virtual shaping channel wall underneath the protrusion and extending parallel to the centroid line.
  • the surface of the protrusion is that portion of the protrusion along the entire protrusion height that first contacts a polymer composition proceeding through a shaping channel containing the protrusion.
  • Protrusion height is a dimension of the protrusion extending from the shaping channel wall to the centroid line of the die.
  • Preferentially heated means heat is directly applied apart from being directly applied elsewhere. For example, a protrusion is preferentially heated if more heat is applied directly into the protrusion than in areas proximate to the protrusion.
  • Multiple means at least two.
  • ASTM refers to an American Society for Testing and Materials test method. The year of the method is either designated by a hyphenated suffix in the method number or, in the absence of such a designation, is the most current year prior to the filing date of this application.
  • the die of the present invention is suitable for use as a solid state drawing die.
  • the die is useful for orienting a polymer composition by drawing the polymer composition through the die.
  • the die comprises a body having opposing ends and defining a shaping channel that provides fluid communication through the body from one end where the shaping channel is an entrance opening in the body to the opposing end where the shaping channel is an exit opening in the body.
  • the portion of the body exposed within the shaping channel serves as shaping channel walls.
  • the shaping channel walls converge (that is, reduce in cross sectional area) along at least a portion of the drawing axis proceeding from the entrance opening to the exit opening of the die's shaping channel.
  • the die is a “converging” die and has a shaping channel with a converging profile.
  • a desirable embodiment of the die includes a shaping channel having a land section that includes the exit opening. Desirably, dimensions of every cross section of the shaping channel all exceed 3 millimeters, preferably 5 millimeters. Dimensions extend from one side to another side of a cross section and go through the cross section's centroid.
  • At least one portion of the die body extends into the shaping channel in the form of a static protrusion.
  • the static protrusion extends along less than a full dimension of a shaping channel cross section. That is, a static protrusion desirably extends into a shaping channel without extending all the way across a shaping channel and extends from a portion of the shaping channel wall that is less than a full dimension of the shaping channel containing that portion of the channel wall.
  • a static protrusion in a shaping channel having a square or rectangular cross section desirably extends less than the width and less than the height of the shaping channel cross section.
  • any dimension of a static protrusion in a shaping channel having a circular cross section desirably extends into the shaping channel less than the diameter of the shaping channel cross section.
  • the solid state drawing die can contain more than one static protrusion. There is no limit as to where multiple static protrusions may be with respect to one another.
  • the die comprises multiple static protrusions sufficient to define a tongue feature in the shaping channel cross section and in a polymer composition drawn through the shaping channel.
  • static protrusions are proximate to one another yet spaced apart by a distance correlating to the tongue feature's width.
  • the polymer composition has opposing sides and the drawing die has static protrusions oriented so as to introduce a tongue feature on one side of the polymer composition and a groove feature, desirably a mating groove feature, on the opposing side of the polymer composition.
  • a mating groove feature fits into the tongue feature of another polymer composition drawn through the same solid state drawing die.
  • Static protrusions in the solid state die of the present invention can have any cross sectional shape conceivable including square, rectangular, triangular, arched, and complex shapes such as dovetail, keyhole and hooked.
  • the static protrusions extend into the shaping channel of the present die to a certain depth that is less than the distance to an opposing protrusion or shaping channel wall.
  • the static protrusion extends into but not all the way across the shaping channel. Depth in this case is a virtual dimension and corresponds to a distance measured perpendicularly from a virtual shaping channel wall extending under the static protrusion.
  • a static protrusion will extend into the shaping channel a distance of three millimeters (mm) or more, preferably six mm or more and can extend to a distance of nine or ten mm or more into the shaping channel from a virtual shaping channel wall extending under the static protrusion.
  • the static protrusion will extend less than all the way across the shaping channel (that is, the static protrusion will not divide a shaping channel cross section into two discrete openings).
  • a static protrusion will extend 50 mm or less into a shaping channel from a virtual shaping channel wall.
  • the static protrusion desirably extends the aforementioned distances into the shaping channel relative to the shaping channel wall at the exit opening of the shaping channel or, if the static protrusion exists at the exit opening, relative to a virtual shaping channel wall extending under the static protrusion at the exit opening of the shaping channel.
  • the indentation will have a depth into the polymer composition of three mm or more, preferably six mm or more and can be nine or ten mm or more and is typically 50 mm or less as the polymer composition exits the die.
  • the static protrusion has a cross sectional area defined in part by the virtual shaping channel wall under the static protrusion.
  • the cross sectional area of the static protrusion can be five square millimeters (mm 2 ) or more, 25 mm 2 or more, 50 mm 2 or more, 100 mm 2 or more 500 mm 2 or more.
  • the cross sectional area of the static protrusion is 1000 mm 2 or less.
  • the drawing die can displace a cross sectional area of 50 mm 2 , even 1000 mm 2 in a solid state material being drawn through the solid state drawing die using a static protrusion without dissociating the polymer composition into discrete (herein, discrete takes on its standard meaning of separate and unconnected) pieces but rather by displacing the solid state material around the static protrusion and redistributing the material within the solid state polymer composition.
  • the static protrusion has an impact surface that is the portion of the static protrusion that a polymer composition first contacts along the static protrusion's height (dimension perpendicular to the virtual shaping channel wall beneath the static protrusion) as it travels through a shaping channel.
  • the impact surface can be, for example, planar or linear (as in a knife edge).
  • the angle the impact surface makes relative to a drawing axis prior (more proximate to the entrance opening) to the impact surface defines the impact angle.
  • the static protrusion can have any impact angle. Lower impact angles less aggressively displace polymer composition and therefore are less likely to tear apart the polymer composition. For that reason, lower impact angles are desirable.
  • one of the surprising discoveries of the present invention is that static protrusions can have impact angles that exceed 30° and can be 45° or more, 60° or more, even 75° or more without dissociating a polymer composition drawn through a drawing die containing the static protrusion into two or more distinct pieces.
  • the impact angle of a static protrusion can be up to and including 90° without dissociating a polymer composition drawn through a drawing die containing the static protrusion into two or more distinct pieces.
  • a 90° impact angle corresponds to a static protrusion having an impact face extending perpendicular to the drawing axis and drawing direction of the polymer in the shaping channel.
  • the static protrusion can extend to essentially any length along the drawing axis in the shaping channel. However, it is desirable that at least a portion of the static protrusion reside within two centimeters, preferably within one centimeter, more preferably within five millimeters of the exit opening of the shaping channel.
  • the static protrusion can extend all the way to the exit opening or even extend out of the exit opening of the shaping channel (thereby extending out of the die).
  • the present die includes a land section containing the exit opening and a static protrusion within the land section.
  • the die can include heating and cooling elements. Suitable heating elements include cartridge heaters and channels through which heating and cooling media can flow.
  • the static protrusion is preferentially heated relative to the rest of the die.
  • a heating element in the static protrusion so as to apply heat to the static protrusion more directly than to the rest of the die.
  • Preferentially heating the static protrusion allows a polymer composition forced against the static protrusion to undergo local softening and become more malleable, which facilitates the ability of the static protrusion to deform a polymer composition drawn through the die without dissociating the polymer composition into two or more distinct pieces.
  • a suitable drawing temperature range for the polymer composition
  • heating a static protrusion with a cartridge heater and then thermally insulating the static protrusion from the rest of the die with an insulator (for example, ceramic material) allows heating of the static protrusion with minimal heating of the rest of the die.
  • Heating a static protrusion to a temperature above a suitable drawing temperature range can, but does not necessarily, result in a reduction or loss of polymer orientation proximate to an indentation since the heating can enable an oriented polymer to relax and a non-oriented polymer to conform without orientation.
  • protrusions in the present die are static during a drawing process
  • the protrusions may be removable from the die itself to facilitate changing protrusion profiles.
  • static protrusions can be part of a removable piece that inserts into a die and is held in place with screws.
  • changing or replacing a static protrusion merely involves unscrewing and removing one protrusion, inserting another and screwing it into place.
  • the process of the present invention is for solid state drawing of a polymer composition.
  • the polymer composition contains one or more than one orientable polymer, which is a polymer that can undergo induced molecular orientation by solid state deformation (solid state drawing).
  • An orientable polymer can be amorphous or semi-crystalline (semi-crystalline polymers have a melt temperature (T m ) and include those polymers known as “crystalline”).
  • Desirable orientable polymers include semi-crystalline polymers, even more desirable are linear polymers (that is, polymers in which chain branching occurs in less than 1 of 1,000 polymer units).
  • Semi-crystalline polymers are particularly desirable because they result in greater increase in strength and modulus than amorphous polymer compositions.
  • Semi-crystalline polymer compositions can result in 4-10 times greater increase in strength and modulus upon orientation over amorphous polymer compositions.
  • Suitable orientable polymers include polymers and copolymers of polystyrene, polycarbonate, polypropylene, polyethylene (including high density polyethylene), polymethylpentane, polytetrafluoroethylene, polyamides, polyesters such as polyethylene terephthalate and polybutylene terephthalate, polycarbonates, polyethylene oxide, polyoxymethylene and blends thereof.
  • Particularly desirably orientable polymers include polyethylene, polypropylene, and polyesters. More particularly desirable orientable polymers include linear polyethylene having a weight-average molecular weight from 50,000 to 3,000,000; especially from 100,000 to 1,500,000, even from 750,000 to 1,500,000.
  • Polyvinylidene fluoride polymers having a weight-average molecular weight of from 200,000 to 800,000, preferably 250,000 to 400,000 are also suitable.
  • Polypropylene (PP)-based polymers are especially desirable for use in the present invention.
  • PP-based polymers generally have a lower density than other orientable polymers. Therefore, PP-based polymers facilitate lighter articles than other orientable polymers. Additionally, PP-based polymers offer greater thermal stability than other orientable olefin polymers. Therefore, PP-based polymers may also form oriented articles having higher thermal stability than oriented articles of other polymers.
  • Suitable PP-based polymers include Zeigler Natta, metallocene and post-metallocene polypropylenes.
  • Suitable PP-based polymers include PP homopolymer; PP random copolymer (with ethylene or other alpha-olefin present from 0.1 to 15 percent by weight of monomers); PP impact copolymers with either PP homopolymer or PP random copolymer matrix of 50-97 percent by weight (wt %) based on impact copolymer weight and with ethylene propylene copolymer rubber present at 3-50 wt % based on impact copolymer weight prepared in-reactor or an impact modifier or random copolymer rubber prepared by copolymerization of two or more alpha olefins prepared in-reactor; PP impact copolymer with either a PP homopolymer or PP random copolymer matrix for 50-97 wt % of the impact copolymer weight and with ethylene-propylene copo
  • the PP-based polymer can be ultra-violet (UV) stabilized, and desirably can also be impact modified.
  • Particularly desirable PP-based polymers are stabilized with organic stabilizers.
  • a combination of low molecular weight and high molecular weight hindered amine-type light stabilizers (HALS) are desirable additives to impart UV stabilization to PP-based polymers.
  • Suitable examples of commercially available stabilizers include IRGASTABTM FS 811, IRGASTABTM FS 812 (IRGASTAB is a trademark of Ciba Specialty Chemicals Corporation).
  • a particularly desirable stabilizer system contains a combination of IRGASTABTM FS 301, TINUVINTM 123 and CHIMASSORBTM 119. (TINUVIN and CHIMASSORB are trademarks of Ciba Specialty chemicals Corporation).
  • the polymer composition may contain fillers including organic, inorganic or a combination of organic and inorganic.
  • filler is a combination of organic and inorganic components it is desirable for the inorganic component to comprise 50 wt % or more, preferably 75 wt % or more of the filler.
  • Suitable organic fillers include cellulosic materials such as wood flour, wood pulp, flax and rice hulls.
  • Suitable inorganic filler include mica, talc (including any or a combination of materials and grades commonly known and available as “talc”), chalk, titanium dioxide, clay, alumina, silica, glass beads, wollastonite, calcium carbonate, magnesium sulfate, barium sulfate, calcium oxysulfate, tin oxide, metal powder, glass powder, pigments, minerals, glass, ceramic, polymeric or carbon reinforcing agent fillers such as glass fibers, micas, talcs, carbon fibers, wollastonite, graphite, silica, magnesium carbonate, alumina, metal fibers, kaolin, silicon carbide, glass flake and the like. Fillers can serve many purposes include serving to enhance flame retardancy, induce cavitation during the drawing process, and provide partial reinforcement of an article.
  • the process requires thermally conditioning the polymer composition prior to drawing it through a solid state drawing die by bringing the polymer composition to a drawing temperature (T d ) within a drawing temperature range that is between the softening temperature (T s ) and 50° C. below T s of the polymer composition and then initiating drawing of the polymer composition while the polymer composition remains within the drawing temperature range.
  • T d drawing temperature
  • T s softening temperature
  • the drawing temperature range can extend to twenty ° C. or more, even thirty ° C. or more below the polymer composition T s . Orientation will not occur to any significant extent if the drawing temperature is above the orientable polymer composition's T s .
  • slow draw rates are necessary if the drawing temperature is too low due to a risk of fracturing the polymer composition during drawing.
  • the drawing temperature is 40° C. or less below the polymer composition's T s to avoid fracturing the polymer composition.
  • the die serves as a solid state drawing die.
  • the polymer composition has a smaller cross section shape (that is, cross sectional area) prior to drawing than the die entrance opening so that it fits into the shaping channel of the die.
  • a draw rate greater than 25.4 centimeters (10 inches) per minute, preferably greater than 127 centimeters (fifty inches) per minute, more preferably greater than 254 centimeters (100 inches) per minute.
  • Faster draw rates provide more efficient production and the necessary stresses in the polymer composition to achieve a desired level of orientation. Faster draw rates can also facilitate cavitation, particularly around filler particles.
  • An upper limit for the draw rate is unknown. Generally, the upper limit for draw rate is limited to that achievable with a reasonable drawing force. The drawing force should be less than the tensile strength of the polymer composition to avoid fracturing the polymer composition.
  • the draw rate is 30.5 meters (1200 inches) per minute or less, more typically 9 meters (360 inches) per minute or less.
  • the polymer composition Upon drawing a polymer composition through the die of the present invention, the polymer composition both undergoes orientation and is shaped by at least one static protrusion so as to have at least one indentation or groove upon exiting the die.
  • the polymer composition may also experience cavitation concomitant with orientation and being shaped or indented by a static protrusion.
  • the static protrusion does not dissociate the polymer composition.
  • the static protrusion imparts a dissociating force over a small area of the solid state polymer composition and forces the solid state polymer composition to part. This is similar to forcing a wedge of a log splitter into a log.
  • the solid state polymer composition parts around the static protrusion without fracturing, unlike a log when thrust upon the wedge of a log splitter.
  • the solid state polymer composition accommodates the static protrusion by displacing in multiple directions having components perpendicular to the drawing direction of the polymer through the shaping channel. Surprisingly, the solid state polymer composition undergoes such displacement while remaining in-tact.
  • calibrating probe Upon exiting the drawing die, it is beneficial to have one or more calibrating probe (calibrator) extend into an indentation or groove formed by a static protrusion in the drawing die, preferably until the polymer composition cools enough to be dimensionally stable.
  • Calibrators can be rods, wheels, plates, or anything that will preserve the dimension of a groove in the polymer composition after the polymer composition exits the die. Without the calibrator in a groove or indentation, the polymer composition may deform as orientation stresses in the polymer composition relax and change the dimension of the groove or indentation.
  • the process of the present invention is useful for fabricating oriented polymeric articles having a shape embodying at least one groove or indentation.
  • an orientable polymer composition by feeding into a twin screw extruder (for example Maplan model TS-92): 50 weight-percent (wt %) INSPIRETM 404 polypropylene (INSPIRE is a trademark of The Dow Chemical Company), 47.5 wt % TC-100 talc (available from Rio Tinto Corporation), and 2.5 wt % TR-251 lubricant (available from Struktol Corporation), with wt % based on total orientable polymer composition weight.
  • the orientable polymer composition has a T s of about 160° C.
  • the converging drawing die for these examples comprise a main converging portion and a land portion that are separable from one another. That allows for changing the die by attaching different land sections to the main converging portion or by replacing the main converging portion with a new design.
  • the land portion in each contains static protrusions which introduce grooves into a solid state polymer composition going through the die.
  • Each example uses the same main converging portion, but utilizes a different land plate at the exit end of the die for the land portion.
  • the different land plates have different static protrusions that introduce a groove or indentation into the orientable polymer composition (which at this point in the drawing process has at least begun to undergo orientation through the converging portion of the die) as it exits the die.
  • FIG. 1 illustrates the main converging portion 10 of the drawing die for use in the present examples.
  • FIG. 1A illustrates an overview of the main converging portion 10 showing entrance opening 20 to shaping channel 30 .
  • FIG. 1B is a cut-away top view of main converging portion 10 as viewed along viewing lines B shown in FIG. 1A and illustrates entrance opening 20 , shaping channel 30 , shaping walls 35 , centroid line 40 , threaded mounting rods 50 and horizontal converging angle ⁇ h .
  • Each shaping channel wall 35 converges towards centroid line 40 at horizontal converging angle ⁇ h of 15°.
  • FIG. 1C is a cut-away side view of main converging portion 10 as viewed along viewing lines C shown in FIG.
  • Entrance opening 20 is rectangular and has a width (W ent ) of 30.5 centimeters (12 inches) and a height (H ent ) of 7.6 centimeters (3 inches).
  • Main die portion 10 has a length (L) of 28 centimeters (11 inches), a width (W) of 46 centimeters (18 inches), and a height (H) of 23 centimeters (9 inches).
  • Threaded mounting rods 50 hold a land plate that mates up to main converging portion 10 of the die in order to form the complete converging die for use in the present examples.
  • the land plates are illustrated in FIGS. 2-6 . Mount the land plates by sliding them onto threaded rods 50 and then holding them flush to main converging portion 10 using nuts on each threaded rod 50 .
  • Example 1 using a die comprising main converging portion 10 from FIG. 1 with a land plate as illustrated in FIG. 2 attached as described above over mounting rods 50 illustrated in FIG. 1 .
  • FIG. 2 illustrates land plate 100 having static protrusions 110 extending into shaping channel 130 of land plate 100 .
  • FIG. 2A illustrates an overall view of land plate 100 viewing into entrance opening 120 .
  • FIG. 2B illustrates a top-view cut-away of the die plate as viewed along viewing line A illustrated in FIG. 2A .
  • Exit opening 140 serves as the exit opening of the converging die when land plate 100 is attached to main converging portion 10 .
  • Static protrusions 110 each have a rectangular planar impact surface 150 that forms impact angle ⁇ i of 27° with virtual shaping channel wall 160 extending beneath each static protrusion 110 .
  • Each static protrusion extends into shaping channel 130 to a depth (D p ) of 1.27 centimeters (0.5 inches) and has a height (H p ) of 0.64 centimeters (0.25 inches) and length (L p ) of 2.54 centimeters (one inch).
  • Shaping channel 130 has a width (W L ) of 15.6 centimeters (6.125 inches) and a height (H L ) of 3.81 centimeters (1.5 inches).
  • the static protrusions 110 introduce an indentation into the polymer composition that is apparent as the polymer composition exits the die.
  • the resulting oriented polymer composition has final dimension of 8.7 centimeters (3.4 inches) wide and 2.2 centimeters (0.87 inches) high.
  • the polymer composition conforms to static protrusions 110 during the drawing process such that the resulting oriented polymer composition has grooves in opposing sides that extend into the oriented polymer composition to a depth of 0.28 centimeters (0.11 inches) with a height or width of 0.33 centimeters (0.13 inches).
  • the resulting grooves are smooth and free of any visible protruding polymer composition fibers.
  • Static protrusions 110 introduce grooves into the solid state polymer composition in a solid state drawing die without dissociating any of the polymer composition into multiple distinct pieces.
  • FIG. 3A illustrates an overall view of land plate 200 viewing into entrance opening 220 .
  • FIG. 3B illustrates a top-view cut-away of the die plate as viewed along viewing line A shown in FIG. 3A .
  • Exit opening 240 serves as the exit opening of the converging die when land plate 200 is attached to main converging portion 10 .
  • FIG. 3 illustrates land plate 200 that is identical to land plate 100 except in the shape of the static protrusion.
  • Static protrusion 210 in land plate 200 has a triangular planar impact surface 250 that initially is a point and expands both in depth (D p ) of penetration into shaping channel and height (H p ).
  • D p and H p are similar to that of land plate 100 .
  • the static protrusions 210 introduce an indentation into the polymer composition that is apparent as the polymer composition exits the die.
  • the rolling disks are 7.6 centimeters (three inches) in diameter and 0.59 centimeters (0.23 inches) thick. Position the rolling disks approximately 50 centimeters, 100 centimeters, 150 centimeters and 200 centimeters from the exit opening of the die and oriented such that the disk inserts into each indentation of the polymer composition and rolls along the bottom of the groove as the polymer is drawn by.
  • the resulting oriented polymer composition has final dimension of 9.7 centimeters (3.81 inches) wide and 2.4 centimeters (0.96 inches) high.
  • the polymer composition conforms to static protrusions 210 during the drawing process such that the resulting oriented polymer composition has grooves in opposing sides that extend into the oriented polymer composition to a depth of 0.58 centimeters (0.23 inches) and a height or width of 0.3 centimeters (0.12 inches).
  • the resulting grooves have a slightly rougher surface texture than Example 1 and any extending polymer fibers are tightly held in place and are short (less than two millimeters).
  • Static protrusions 210 introduce grooves into the solid state polymer composition in a solid state drawing die without dissociating any of the polymer composition into multiple distinct pieces.
  • FIG. 4A illustrates an overall view of land plate 300 viewing into entrance opening 320 .
  • FIG. 4B illustrates a top-view cut-away of the die plate as viewed along viewing line A shown in FIG. 4A .
  • Exit opening 340 serves as the exit opening of the converging die when land plate 300 is attached to main converging portion 10 .
  • FIG. 4 illustrates land plate 300 that is similar to land plate 100 except: (1) the impact face 350 of static protrusions 310 have been rounded in gradual fashion such that there is minimal rounding proximate to shaping channel wall 380 and rounding reaches a 0.32 centimeters (0.125 inch) radius of curvature where static protrusion 310 is most remote from shaping channel wall 380 ; (2) impact angle ⁇ i is 37°; and (3) the depth (D p ) of static protrusion 310 is 0.9 centimeters (0.75 inches).
  • the static protrusions 310 introduce an indentation into the polymer composition that is apparent as the polymer composition exits the die.
  • the rolling disks are 7.6 centimeters (three inches) in diameter and 0.59 centimeters (0.23 inches) thick. Position the rolling disks approximately 50 centimeters, 100 centimeters, 150 centimeters and 200 centimeters from the exit opening of the die and oriented such that the disk inserts into each indentation of the polymer composition and rolls along the bottom of the groove as the polymer is drawn by.
  • the resulting oriented polymer composition has final dimension of 9.9 centimeters (3.91 inches) wide and 2.5 centimeters (0.98 inches) high.
  • the polymer composition conforms to static protrusions 310 during the drawing process such that the resulting oriented polymer composition has grooves in opposing sides that extend into the oriented polymer composition to a depth of 0.76 centimeters (0.3 inches) and a height or width of 0.4 centimeters (0.16 inches).
  • the resulting grooves have a slightly rougher surface texture than Example 1 and any extending polymer fibers are tightly held in place and are short (less than two millimeters).
  • Static protrusions 310 introduce grooves into the solid state polymer composition in a solid state drawing die without dissociating any of the polymer composition into multiple distinct pieces.
  • FIG. 5A illustrates an overall view of land plate 400 viewing into entrance opening 420 .
  • FIG. 5B illustrates a top-view cut-away of the die plate as viewed along viewing line A shown in FIG. 5A .
  • Exit opening 440 serves as the exit opening of the converging die when land plate 400 is attached to main converging portion 10 .
  • FIG. 5 illustrates land plate 400 that is identical to land plate 200 except: (1) the impact face 450 of static protrusions 410 have been rounded in gradual fashion such that there is minimal rounding proximate to shaping channel wall 480 and rounding reaches a 0.32 centimeters (0.125 inch) radius of curvature where static protrusion 410 is most remote from shaping channel wall 380 ; (2) impact angle ⁇ i is 37°; and (3) the depth (D p ) of static protrusion 410 is 0.9 centimeters (0.75 inches).
  • the static protrusions 410 introduce an indentation into the polymer composition that is apparent as the polymer composition exits the die.
  • the rolling disks are 7.6 centimeters (three inches) in diameter and 0.59 centimeters (0.23 inches) thick. Position the rolling disks approximately 50 centimeters, 100 centimeters, 150 centimeters and 200 centimeters from the exit opening of the die and oriented such that the disk inserts into each indentation of the polymer composition and rolls along the bottom of the groove as the polymer is drawn by.
  • the resulting oriented polymer composition has final dimension of 10.6 centimeters (4.16 inches) wide and 2.7 centimeters (1.07 inches) high.
  • the polymer composition conforms to static protrusions 410 during the drawing process such that the resulting oriented polymer composition has grooves in opposing sides that extend into the oriented polymer composition to a depth of 1.09 centimeters (0.43 inches) and a height or width of 0.38 centimeters (0.15 inches).
  • the resulting grooves have a slightly rougher surface texture than Example 1 and any extending polymer fibers are tightly held in place and are short (less than two millimeters).
  • Static protrusions 410 introduce grooves into the solid state polymer composition in a solid state drawing die without dissociating any of the polymer composition into multiple distinct pieces.
  • Example 5 using a die comprising main converging portion 10 from FIG. 1 with a land plate as illustrated in FIG. 6 attached as described above over mounting rods 50 illustrated in FIG. 1 .
  • FIG. 6 illustrates land plate 500 having static protrusions 510 extending into shaping channel 530 of land plate 500 .
  • FIG. 6A illustrates an overall view of land plate 500 viewing into entrance opening 520 .
  • FIG. 6 B illustrates a top-view cut-away of the die plate as viewed along viewing line A illustrated in FIG. 6A .
  • Exit opening 540 serves as the exit opening of the converging die when land plate 500 is attached to main converging portion 10 .
  • Static protrusions 510 each have a rectangular planar impact surface 550 that forms impact angle ⁇ i of 90° with virtual shaping channel wall 560 extending beneath each static protrusion 510 .
  • Each static protrusion extends into shaping channel 530 to a depth (D p ) of 1.9 centimeters (0.75 inches) and has a height (H p ) of 0.64 centimeters (0.25 inches) and length (L p ) of 2.54 centimeters (one inch).
  • Shaping channel 530 has a width (W L ) of 15.6 centimeters (6.125 inches) and a height (H L ) of 3.81 centimeters (1.5 inches).
  • the static protrusions 510 introduce an indentation into the polymer composition that is apparent as the polymer composition exits the die.
  • the rolling disks are 7.6 centimeters (three inches) in diameter and 0.59 centimeters (0.23 inches) thick. Position the rolling disks approximately 50 centimeters, 100 centimeters, 150 centimeters and 200 centimeters from the exit opening of the die and oriented such that the disk inserts into each indentation of the polymer composition and rolls along the bottom of the groove as the polymer is drawn by.
  • the resulting oriented polymer composition has final dimension of 9.0 centimeters (3.53 inches) wide and 2.1 centimeters (0.82 inches) high.
  • the polymer composition conforms to static protrusions 510 during the drawing process such that the resulting oriented polymer composition has grooves in opposing sides that extend into the oriented polymer composition to a depth of 1.1 centimeters (0.42 inches) with a height or width of 0.38 centimeters (0.15 inches).
  • Static protrusions 510 introduce grooves into the solid state polymer composition in a solid state drawing die without dissociating any of the polymer composition into multiple distinct pieces.
  • Example 6 using a die comprising main converging portion 10 from FIG. 1 with a land plate similar to those of Examples 1-5. Centered on one side of the die is a static protrusion having a rounded triangular profile having an impact angle of 21°. The static protrusion extends to a depth of 0.97 centimeters (0.38 inches) into the shaping channel with a length of 2.54 centimeters (one inch) and a width of 0.94 centimeters (0.37 inches). On an opposing side of the land plate are two static protrusions having planar rectangular faces. Both static protrusions have an impact angle of 21°, one from the top shaping channel wall and one from the bottom shaping channel wall of the land plate.
  • the static protrusions extend into the shaping channel 1.5 centimeters (0.58 inches) from the side shaping channel wall and 0.97 centimeters (0.38 inches) from the top or bottom shaping channel wall. There is a space between the static protrusions along the side of the shaping channel that defines a tongue shaping channel cross section.
  • the rolling disks are 7.6 centimeters (three inches) in diameter and 0.59 centimeters (0.23 inches) thick. Position the rolling disks approximately 50 centimeters, 100 centimeters, 150 centimeters and 200 centimeters from the exit opening of the die and oriented such that the disk inserts into the groove of the polymer composition and rolls along the bottom of the groove as the polymer is drawn by.
  • the resulting oriented polymer composition has final dimension of 8.7 centimeters (3.42 inches) wide and 2.5 centimeters (0.97 inches) high.
  • the polymer composition conforms to static protrusions in the die plate during the drawing process such that the resulting oriented polymer composition has grooves defining a tongue on one side and a mating groove on an opposing side of the oriented polymer composition cross section.
  • the resulting grooves have a slightly rougher surface texture than Example 1 and any extending polymer fibers are tightly held in place and are short (less than two millimeters).
  • the resulting grooves have a slightly rougher surface texture than Example 1 and any extending polymer fibers are tightly held in place and are short (less than two millimeters).
  • the resulting grooves have a slightly rougher surface texture than Example 1 and any extending polymer fibers are tightly held in place and are short (less than two millimeters).
  • the static protrusion in the tongue and groove die introduce grooves into the solid state polymer composition in a solid state drawing die without dissociating any of the polymer composition into multiple distinct pieces.

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WO2013003490A1 (fr) * 2011-06-28 2013-01-03 James Hardie Technology Limited Nouvel article composite polymère orienté, composition et procédé de fabrication
ITAN20120010A1 (it) * 2012-02-02 2013-08-03 Janus Energy S R L Pannelli riscaldanti con fessure di drenaggio
US20130259968A1 (en) * 2012-03-28 2013-10-03 Craig Wojcicki Static-dissipative foam extrusion calibration with minimized expansion loss
WO2015063365A1 (fr) * 2013-10-31 2015-05-07 Upm-Kymmene Corporation Procédé de fabrication d'un composite plastique de fibres naturelles
US9713894B2 (en) 2012-06-28 2017-07-25 Dow Global Technologies Llc System, method and apparatus for producing a multi-layer, microcapillary film

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